Heat exchanger with removable core assembly

ABSTRACT

A heat exchanger is having: a housing having a first housing inlet, a second housing inlet, a first housing outlet, and a second housing outlet; and a core assembly disposed within the housing and removably connected to the housing, the core assembly comprises: a first fluid passage fluidly connecting the first housing inlet to the first housing outlet and a second fluid passage fluidly connecting the second housing inlet to the second housing outlet. The first fluid passage is thermally connected to the second fluid passage.

BACKGROUND

The present invention relates to heat exchanger arrangements, and more particularly to a core assembly for a heat exchanger.

A heat exchanger is utilized to cool or heat a fluid medium by flowing two fluid mediums adjacent to each other through a core assembly. The heat exchanger may be employed in various applications and subjected to specific thermal requirements. The dimensions of the components of the heat exchanger, and more particularly the core assembly play a significant role in meeting the operating requirements and in withstanding the thermal requirements noted above. This often means that the core designed for each specific application. Thus restricting the use of the overall heat exchanger to other applications outside of the design range of the core. A more cost efficient and flexible heat exchanger design is greatly desired.

SUMMARY

According to one embodiment, a heat exchanger is provided. The heat exchanger having: a housing having a first housing inlet, a second housing inlet, a first housing outlet, and a second housing outlet; and a core assembly disposed within the housing and removably connected to the housing, the core assembly comprises: a first fluid passage fluidly connecting the first housing inlet to the first housing outlet and a second fluid passage fluidly connecting the second housing inlet to the second housing outlet. The first fluid passage is thermally connected to the second fluid passage.

In addition to one or more of the features described above, or as an alternative, further embodiments of the heat exchanger may include that the housing further includes a top portion having a mounting flange and an opposing bottom portion; and the core assembly further comprises a top side having a core flange and an opposing bottom side. The core flange mounts onto the opposing mounting flange and the bottom side of the core assembly abuts the bottom portion of the housing when the core assembly is disposed within the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the heat exchanger may include that the core flange of the core assembly is removably connected to the mounting flange of the housing by a plurality of fasteners.

In addition to one or more of the features described above, or as an alternative, further embodiments of the heat exchanger may include a first seal interposed between the bottom side of the core assembly and the bottom portion of the housing, the first seal being configured to seal the fluid connection between the second housing inlet and the second fluid passage and seal the fluid connection between the second housing outlet and the second fluid passage when the core assembly is disposed within the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the heat exchanger may include that the core assembly further comprises a knife edge located on the bottom part of the core assembly and configured to compress the first seal when the core assembly is disposed within the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the heat exchanger may include a second seal interposed between the core flange of the core assembly and the mounting flange of the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the heat exchanger may include corner seals at each corner of the core assembly, the corner seals being configured to seal the interface between an inner surface of the housing and an outer surface of the core assembly when the core assembly is disposed within the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the heat exchanger may include that the housing further includes a tapered pin; and the core assembly further includes rings configured to fit around the tapered pin when the core assembly is disposed within the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the heat exchanger may include that the core assembly is cuboid in shape having a top side, an opposing bottom side, and four sides interposed between the top side and the bottom side, the bottom side includes a second core inlet aligned with the second inlet and a second core outlet aligned with the second housing outlet when the core assembly is disposed within the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the heat exchanger may include that the second fluid passage of the core assembly includes at least two passes across the flow direction of the first fluid passage.

According to another embodiment, a method of assembling a heat exchanger is provided. The method including: forming a housing having a first housing inlet, a second housing inlet, a first housing outlet, and a second housing outlet; positioning a core assembly within the housing, the core assembly includes: a first fluid passage fluidly connecting the first housing inlet to the first housing outlet and a second fluid passage fluidly connecting the second housing inlet to the second housing outlet, the first fluid passage is thermally connected to the second fluid passage; and removably connecting the core assembly to the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the method may include forming a mounting flange on a top portion of the housing, the top portion being opposite a bottom portion. The core assembly further includes a top side having a core flange and an opposing bottom side, the core flange mounts onto the opposing mounting flange and the bottom side of the core assembly abuts the bottom portion of the housing when the core assembly is disposed within the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the method may include that the core flange of the core assembly is removably connected to the mounting flange of the housing by a plurality of fasteners.

In addition to one or more of the features described above, or as an alternative, further embodiments of the method may include positioning a first seal interposed between the bottom side of the core assembly and the bottom portion of the housing, the first seal being configured to seal the fluid connection between the second housing inlet and the second fluid passage and seal the fluid connection between the second housing outlet and the second fluid passage when the core assembly is disposed within the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the method may include that the core assembly further includes a knife edge located on the bottom part of the core assembly and configured to compress the first seal when the core assembly is disposed within the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the method may include positioning a second seal interposed between the core flange of the core assembly and the mounting flange of the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the method may include positioning corner seals at each corner of the core assembly, the corner seals being configured to seal the interface between an inner surface of the housing and an outer surface of the core assembly when the core assembly is disposed within the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the method may include that the housing further comprises a tapered pin; and the core assembly further comprises rings configured to fit around the tapered pin when the core assembly is disposed within the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the method may include that the core assembly is cuboid in shape having a top side, an opposing bottom side, and four sides interposed between the top side and the bottom side, the bottom side includes a second core inlet aligned with the second inlet and a second core outlet aligned with the second housing outlet when the core assembly is disposed within the housing.

In addition to one or more of the features described above, or as an alternative, further embodiments of the method may include that the second fluid passage of the core assembly includes at least two passes across the flow direction of the first fluid passage.

Technical effects of embodiments of the present disclosure include a heat exchanger having a removable core assembly.

The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, that the following description and drawings are intended to be illustrative and explanatory in nature and non-limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter is particularly pointed out and distinctly claimed at the conclusion of the specification. The foregoing and other features, and advantages of the present disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is an isometric view of a heat exchanger, according to an embodiment of the present disclosure;

FIG. 2 is an exploded view of the heat exchanger of FIG. 1, according to an embodiment of the present disclosure;

FIG. 3 is a cross-sectional side view of the heat exchanger of FIG. 1 taken along line 3-3, according to an embodiment of the present disclosure;

FIG. 4 is an enlarged cross-sectional side view of the heat exchanger of FIG. 3, according to an embodiment of the present disclosure;

FIG. 5 is a cross-sectional top view of the heat exchanger of FIG. 1 taken along line 5-5, according to an embodiment of the present disclosure;

FIG. 6 is an enlarged cross-sectional top view of the heat exchanger of FIG. 5, according to an embodiment of the present disclosure;

FIG. 7 is a cross-sectional top view of the heat exchanger of FIG. 1 taken along line 7-7, according to an embodiment of the present disclosure; and

FIG. 8 is a flow process illustrating a method of manufacturing the heat exchanger of FIGS. 1-7, according to an embodiment of the present disclosure.

The detailed description explains embodiments of the present disclosure, together with advantages and features, by way of example with reference to the drawings.

DETAILED DESCRIPTION

Referring to FIGS. 1-7, a heat exchanger 100 is illustrated. The heat exchanger 100 may be used in conjunction with an assembly or system of a vehicle, such as an aircraft, however, it is contemplated that other vehicles may benefit from the embodiments described herein. In one embodiment, the heat exchanger 100 is part of an air conditioning system or refrigeration system of an aircraft.

The heat exchanger 100 includes a core assembly 150 disposed within the housing 120 and removably connected to the housing 120. The core assembly 150 may be removably connected to the housing 120 by a plurality of fasteners 190, as seen in FIG. 1. The housing 120 includes a top portion 120 a, a bottom portion 120 b, an inner surface 120 c, and an outer surface 120 d. The housing 120 may also include a mounting point 104 to mount the housing 120 to a structural support, such as, for example, a structural frame of an aircraft. The housing 120 also includes a first housing inlet 122 for a first fluid 10, such as, for example, cold air from an air cycle machine (ACM) turbine (not shown). A mixer 110 may be located at the first housing inlet 122, as seen in FIGS. 1-3, 5, and 7. The housing 120 also includes a first housing outlet 128 for the first fluid 10 to exit the heat exchanger 100. The first housing outlet 128 may lead the first fluid 10 overboard or outside a vehicle. A first fluid passage 153, located in the core assembly 150, fluidly connects the first housing inlet 122 to the first housing outlet 128. Thus, the first fluid 10 flows F1 from an ACM turbine through the mixer 110 and into the core assembly 150 through the first housing inlet 122. Once the first fluid 10 has flowed F6 through the first fluid passage 153 of the core assembly 150, the first fluid 10 flows F5 out of the heat exchanger 100 through the first housing outlet 128.

Additionally, the housing includes a second housing inlet 124 for a second fluid 20, such as, for example, warm air from an ACM compressor (not shown). The housing 120 also includes a second housing outlet 126 for the second fluid 20 to exit the heat exchanger 100. The second housing outlet 126 may lead the second fluid 20 to a cabin of a vehicle or aircraft. A second fluid passage 163, located in the core assembly 150, fluidly connects the second housing inlet 124 to the second housing outlet 126. Thus, the second fluid 20 flows F2 from an ACM compressor into the core assembly 150 through the second housing inlet 124. Once the second fluid 20 has flowed F3 through the second fluid passage 163 of the core assembly 150, the second fluid 20 flows F4 out of the heat exchanger 100 through the second housing outlet 126.

The core assembly 150 includes a top side 150 a, a bottom side 150 b, an inner surface 150 c, and an outer surface 150 d. The bottom side 150 b of the core assembly 150 abuts the bottom portion 120 b of the housing 120 when the core assembly 150 is disposed within the housing 120. The core assembly 150 includes core 160 having a first fluid passage 153 having a first core inlet 154 and a first core outlet 156. As may be appreciated by one of skill in the art, the core 160 may include various designs for the exchange of heat between the first fluid passage 153 and the second fluid passage including various core types and header types. The core assembly also includes a second fluid passage 163 having a second core inlet 164 and a second core outlet 166. The first fluid passage 153 is thermally connected to the second fluid passage 163. When the core assembly 150 is disposed within the housing 120 the first core inlet 154 is aligned with the first housing inlet 122, the second core inlet 164 is aligned with the second housing inlet 124, the first core outlet 156 is aligned with the first housing outlet 128, and the second core outlet 166 is aligned with the second housing outlet 126 as seen in FIG. 3. A first seal 172 is interposed between the bottom side 150 b of the core assembly 150 and the bottom portion 120 b of the housing 120, as seen in FIGS. 4 and 7. The first seal 172 is configured to seal the fluid connections between the second housing inlet 124 and the second fluid passage 163 and the fluid connection between the second core outlet 166 and the second fluid passage 163. In other words, the first seal 172 is configured to seal the fluid connections between the second housing inlet 124 and the second core inlet 164 and also seal the fluid connection between the second core outlet 166 and the second housing outlet 126. In an embodiment, the first seal 172 may be a compression seal and/or hollow tube seal.

Proximate the outer surface 150 d of the core assembly 150 portions, of the first fluid passage 153 and the second fluid passage 163 that compose the core 160 may form an outer edge 155 of the core 160. The outer edge 155 may provide additional structural support to the core assembly 150. The outer edge 155 may include a knife edge 155 a proximate the bottom 150 b of the core assembly 150. The knife edge 155 a is configured to compress the first seal 172. The outer edge 155, may also include rings 155 b configured to fit around a tapered pin 130, as seen in FIG. 4. In the illustrated embodiment, the heat exchanger 100 includes four tapered pins 130 affixed to the bottom portion 120 b of the housing 120. The tapered pins 130 are configured to help align the core assembly 150 within the housing 120. As the core assembly 150 is inserted into the housing 120 the rings 155 b slide in around the tapered pins 130. In operation, heat may cause the core assembly 150 to expand and contract and as this occurs the rings 155 b are free to slide up D1 and down D2 on the pins.

In the illustrated embodiment the core 160 has a two pass design where the second fluid passage 163 of the core assembly 150 includes at least two passes across the flow direction F6 of the first fluid passage 153. The two pass design allows the second fluid 20 to flow F3 through the core 160 twice within the second fluid passage 163 before exiting the core 160. The second fluid passage 163 utilizes a domed header 157, located at the top side 150 a, to redirect the flow F3 one-hundred and eighty degrees from the second core inlet 164 to the second fluid exit 166, thus allowing the second fluid 20 to pass through the core 160 twice. The first fluid 10 flows F6 through the first fluid passage 153, which is arranged perpendicular to the second fluid passage 163. As may be appreciated by one of skill in the art there may be multiple first fluid passages 153 and multiple second fluid passages 163; however a single first fluid passage 153 and a single second fluid passage 163 are shown for simplicity. Further, as may be appreciated by one of skill in the art the core 160 may include a variety of different fin designs and patterns for the first fluid passage 153 and the second fluid passage 160 to achieve the desired thermal transfer between the fluid passages 153, 163.

As mentioned above, the core assembly 150 is removably connected to the housing 120, which means that the core assembly 150 may be inserted into the housing 120 and secured to the housing 120; and then the core assembly 150 may be unsecured from the housing 120 and removed from the housing 120. As also mentioned above, the core assembly 150 is secured to the housing 120 by a plurality of fasteners 190. As seen in FIG. 2, a core flange 159 on the core assembly 150 mounts onto an opposing mounting flange 129 on the housing 120 and the fasteners 190 secure the core flange 159 to the mounting flange 129. The mounting flange 129 is located proximate the top portion 120 a of the housing 120. In an embodiment, the fasteners may be a bolt that screws into pre-drilled holes in the mounting flange 129. A second seal 174 is interposed between the core flange 159 and the mounting flange 129, as seen in FIG. 3. The second seal 174 is configured to act as a gasket and seal the interface between the core flange 174 and the mounting flange 129. The second seal 174 may be composed of an elastomeric material.

The core assembly 150 also includes a plurality of corner seals 180 located at each corner 150 e of the core assembly 150, as seen in FIG. 5, to provide air sealing at each corner 150 e when the core assembly 150 disposed within the housing 120. The corner seals 180 may also help guide the core assembly 150 during installation and removal of the core assembly 150 from the housing 120. The corner seals 180 are configured to seal the interface between an inner surface 120 c of the housing 120 and an outer surface 120 d of the core assembly 150 when the core assembly 150 is disposed within the housing 120. The corner seals 180 may be composed of an elastomeric or similar material. The corner seals 180 may have a corner fitting 186 help fit with each corner 150 e of the core assembly 150. The corner seals 180 may be fixedly connected to the outer surface 150 d of the core assembly 150 at each corner 150 e. The corner seals 180 may be fixedly connected to the outer surface 150 d by an adhesive (not shown) applied between the corner fitting 186 and the corner 150. The corner seal 180 may also include teeth 182, as seen in FIG. 6, to aid in sealing between the corner seal 180 and the inner surface 120 c of the housing 120. The teeth 182 may also slide relative to the inner surface 120 c of the core assembly 150 is inserted into the housing 120 and removed from the housing 120. Additionally, the corner seal 180 may include a center core 188. Advantageously, the center core 188 may aid in compression and also provide weight savings. In the illustrated embodiment, the core assembly 150 is cuboid in shape having six sides including the top side 150 a and an opposing bottom side 150 b having the second core inlet 164 and the second core outlet 166. The four sides interposed between the top side 150 a and the bottom side 150 b includes two opposing side walls 151, the first core inlet 154, and the first core outlet 156. The corner seals 180 are each located at the four corners 150 e of the four sides interposed between the topside 150 a and the bottom side 150 b.

Referring now to FIG. 8, while referencing components of the heat exchanger 100 of FIGS. 1-7, FIG. 8 shows a flow process illustrating a method 800 of assembling the heat exchanger 100 of FIGS. 1-7. At block 804, the housing 120 is formed. The housing 120 may be formed by various manufacturing methods including but not limited to molds, machining, additive manufacturing, and/or any other method known to one of skill in the art. As discussed above, the housing has a first housing inlet 122, a second housing inlet 124, a first housing outlet 128, and a second housing outlet 126. At block 806, the core assembly 150 is positioned within the housing. As mentioned above, the core assembly 150 comprises a first fluid passage 153 fluidly connecting the first housing inlet 122 to the first housing outlet 128 and a second fluid passage 163 fluidly connecting the second housing inlet 124 to the second housing outlet 126. The first fluid passage 153 is thermally connected to the second fluid passage 163.

At block 808, the core assembly 150 is removably connected to the housing 120. As discussed above, fasteners 190 may be used to removably connect the core assembly 150 to the housing 120. At block 810, the mounting flange 129 is formed on the top portion 120 a of the housing 120. The top portion 120 a is opposite the bottom portion 120 b. As mentioned above, the core assembly 150 further comprises a top side 150 a having a core flange 159 and an opposing bottom side 150 b. The core flange 159 mounts onto the opposing mounting flange 129 and the bottom side 150 b of the core assembly 150 abuts the bottom portion 120 b of the housing 120 when the core assembly 150 is disposed within the housing 120.

At block 812, the first seal 172 is positioned interposed between the bottom side 150 b of the core assembly 150 and the bottom portion 120 b of the housing 120. The first seal 172 being configured to seal the fluid connection between the second housing inlet 124 and the second fluid passage 163 and seal the fluid connection between the second housing outlet 126 and the second fluid passage 163 when the core assembly 150 is disposed within the housing 120. At block 814, the second seal 174 is positioned interposed between the flange 159 of the core assembly 150 and the mounting flange 129 of the housing 120.

While the above description has described the flow process of FIG. 8 in a particular order, it should be appreciated that unless otherwise specifically required in the attached claims that the ordering of the steps may be varied.

While the present disclosure has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the present disclosure is not limited to such disclosed embodiments. Rather, the present disclosure can be modified to incorporate any number of variations, alterations, substitutions, combinations, sub-combinations, or equivalent arrangements not heretofore described, but which are commensurate with the scope of the present disclosure. Additionally, while various embodiments of the present disclosure have been described, it is to be understood that aspects of the present disclosure may include only some of the described embodiments. Accordingly, the present disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. 

What is claimed is:
 1. A heat exchanger, comprising: a housing having a first housing inlet, a second housing inlet, a first housing outlet, and a second housing outlet; and a core assembly disposed within the housing and removably connected to the housing, the core assembly comprises: a first fluid passage fluidly connecting the first housing inlet to the first housing outlet and a second fluid passage fluidly connecting the second housing inlet to the second housing outlet, wherein the first fluid passage is thermally connected to the second fluid passage.
 2. The heat exchanger of claim 1, wherein the housing further comprises a top portion having a mounting flange and an opposing bottom portion; and the core assembly further comprises a top side having a core flange and an opposing bottom side, the core flange mounts onto the opposing mounting flange and the bottom side of the core assembly abuts the bottom portion of the housing when the core assembly is disposed within the housing.
 3. The heat exchanger of claim 2, wherein the core flange of the core assembly is removably connected to the mounting flange of the housing by a plurality of fasteners.
 4. The heat exchanger of claim 2, further comprising: a first seal interposed between the bottom side of the core assembly and the bottom portion of the housing, the first seal being configured to seal the fluid connection between the second housing inlet and the second fluid passage and seal the fluid connection between the second housing outlet and the second fluid passage when the core assembly is disposed within the housing.
 5. The heat exchanger of claim 2, wherein the core assembly further comprises a knife edge located on the bottom part of the core assembly and configured to compress the first seal when the core assembly is disposed within the housing.
 6. The heat exchanger of claim 2, further comprising: a second seal interposed between the core flange of the core assembly and the mounting flange of the housing.
 7. The heat exchanger of claim 1, further comprising: corner seals at each corner of the core assembly, the corner seals being configured to seal the interface between an inner surface of the housing and an outer surface of the core assembly when the core assembly is disposed within the housing.
 8. The heat exchanger of claim 1, wherein the housing further comprises a tapered pin; and the core assembly further comprises rings configured to fit around the tapered pin when the core assembly is disposed within the housing.
 9. The heat exchanger of claim 1, wherein the core assembly is cuboid in shape having a top side, an opposing bottom side, and four sides interposed between the top side and the bottom side, the bottom side includes a second core inlet aligned with the second inlet and a second core outlet aligned with the second housing outlet when the core assembly is disposed within the housing.
 10. The heat exchanger of claim 1, wherein the second fluid passage of the core assembly includes at least two passes across the flow direction of the first fluid passage.
 11. A method of assembling a heat exchanger, the method comprising: forming a housing having a first housing inlet, a second housing inlet, a first housing outlet, and a second housing outlet; positioning a core assembly within the housing, the core assembly comprises: a first fluid passage fluidly connecting the first housing inlet to the first housing outlet and a second fluid passage fluidly connecting the second housing inlet to the second housing outlet, the first fluid passage is thermally connected to the second fluid passage; and removably connecting the core assembly to the housing.
 12. The method of claim 11, further comprising: forming a mounting flange on a top portion of the housing, the top portion being opposite a bottom portion; and wherein the core assembly further comprises a top side having a core flange and an opposing bottom side, the core flange mounts onto the opposing mounting flange and the bottom side of the core assembly abuts the bottom portion of the housing when the core assembly is disposed within the housing.
 13. The method of claim 12, wherein the core flange of the core assembly is removably connected to the mounting flange of the housing by a plurality of fasteners.
 14. The method of claim 12, further comprising: positioning a first seal interposed between the bottom side of the core assembly and the bottom portion of the housing, the first seal being configured to seal the fluid connection between the second housing inlet and the second fluid passage and seal the fluid connection between the second housing outlet and the second fluid passage when the core assembly is disposed within the housing.
 15. The method of claim 12, wherein the core assembly further comprises a knife edge located on the bottom part of the core assembly and configured to compress the first seal when the core assembly is disposed within the housing.
 16. The method of claim 12, further comprising: positioning a second seal interposed between the core flange of the core assembly and the mounting flange of the housing.
 17. The method of claim 11, further comprising: positioning corner seals at each corner of the core assembly, the corner seals being configured to seal the interface between an inner surface of the housing and an outer surface of the core assembly when the core assembly is disposed within the housing.
 18. The method of claim 11, wherein the housing further comprises a tapered pin; and the core assembly further comprises rings configured to fit around the tapered pin when the core assembly is disposed within the housing.
 19. The method of claim 11, wherein the core assembly is cuboid in shape having a top side, an opposing bottom side, and four sides interposed between the top side and the bottom side, the bottom side includes a second core inlet aligned with the second inlet and a second core outlet aligned with the second housing outlet when the core assembly is disposed within the housing.
 20. The method of claim 11, wherein the second fluid passage of the core assembly includes at least two passes across the flow direction of the first fluid passage. 